Heat exchanger

ABSTRACT

Disclosed herein is a heat exchange apparatus, which comprises a hollow blade member having a first fluid inlet and a first fluid outlet and a first fluid passageway for a first fluid that extends between the inlet and the outlet. The blade member is sized and shaped to be located in a second fluid passageway for a second fluid. The blade member is configured to enhance thermal energy transfer between the fluids as they flow along their respective passageways.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing dates of U.S. provisional patent application Ser. No. 60/964,658, filed Aug. 14, 2007; U.S. provisional patent application Ser. No. 60/994,039, filed Sep. 17, 2007; U.S. provisional patent application Ser. No. 61/008,766, filed Dec. 21, 2007; and U.S. provisional patent application Ser. No. 61/134,666, filed Jul. 11, 2008, the disclosures of which are hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention concerns heat exchangers, and more particularly to blade-type heat exchangers for recovering heat from fluids.

BACKGROUND OF THE INVENTION

Heat exchangers are well-known and widely used in a number of environments to recover thermal energy from fluids. The thermal energy, if not recovered, would be lost to the environment. Generally speaking, heat exchangers work by transferring heat from one fluid to another via a solid wall, which separates the two fluids. This straightforward principle has been used to recover heat from waste water (so called “grey water”) in, for example, household shower and bath systems. A number of designs of heat exchangers that have been used with household shower/bath systems are described as follows.

U.S. Pat. No. 5,143,149 issued to Kronberg on Sep. 1, 1992 concerns a heat recovery system that includes a heat exchanger and a mixing valve. The heat exchanger appears to include a drain trap with an inner coiled tube, a baffle plate and a waste water outlet. The inner coiled tube includes a cold water inlet and a pre-heated water outlet in fluid communication with each other and is coiled around the inside wall of a cylindrical member. A waste water inlet is located in the drain trap such that waste water enters the cylinder through the inlet, contacts the baffle plate and is deflected away from a solid central portion towards a perforated outer region such that the waste water gradually moves downwardly through the cylinder until it reaches the bottom. Cold water located in the coiled tube moves in a generally upward direction opposite to the waste water as it flows downwardly over the coiled tube to heat the cold water. Heat exchange appears to take place through the walls of the coiled tube. The heated water then exits the heat exchanger via the outlet. The design is simple and relies on the counter-flow principal of heat exchange across a thermally conductive wall of the coiled pipe. While this apparatus uses the heat from waste drain water to heat cold water via a heat exchanger, it does so by direct contact of the waste water with the coiled cold water tube.

U.S. Pat. No. 4,821,793 issued to Sheffield on Apr. 18, 1989 discloses a tub and shower floor heat exchanger in which a heat exchanger cover is supported on the tub floor by a number of supports, each having an opening therein. The heat exchanger cover is disposed away from the tub floor and includes a gap between the cover and the tub floor. A heat exchange tube is connected to a cold water supply line, the heat exchange tube being arranged directly beneath the heat exchanger cover. Water flowing from a shower head strikes the tub bottom and, as waste water flows towards a drain hole, it is forced back and forth over an extended path by means of the supports which serve as a baffle system. As the waste water moves through the baffle system it moves through the openings and is maintained in a heat exchange relationship with the heat exchange tube over an extended period of time, thereby heating the cold water in the heat exchange tube, which is then fed back to a water line. Disadvantageously, a user of the tub may trip over the raised heat exchanger cover. The tub may also be difficult to clean and maintain.

U.S. Pat. No. 4,619,311 issued to Vasile et al. on Oct. 28, 1986 discloses a counter-flow heat exchanger system in which waste water exits a shower tub via an essentially vertical waste pipe. A lower portion of the waste pipe is surrounded by a jacket into which is fed cold water in a coaxial counter-flow orientation such that waste water travelling down the waste water pipe exchanges its heat with the cold water travelling up the jacket thereby heating the cold water by heat transfer across the waste water pipe wall. The heated water exits directly to the shower system or moves to a hot water heater tank.

U.S. Pat. No. 4,472,372 issued to Hunter on Feb. 8, 1983 discloses a heat exchanger that is located in a drain pipe of a shower bath. A cylindrical member is in communication with the drain hole and includes, on the interior, a coiled heat conducting conduit. The coiled conduit includes a coiled copper tube which extends the full length of the cylindrical housing and a second heat conducting coil that is disposed within the annulus of the first heat conducting coil. The coils are each fed by a common inlet conduit which feeds cold water through the coiled conduits such that waste water flowing into the cylindrical member heats the cold water flowing through the coils which then exits via a common outlet towards the mixing valve of the shower unit. A baffle in the form of a central core member is disposed within the annulus of the central coil and appears to cause the water flowing from the drain pipe to be maintained in contact with both coils so as to maximize heat transfer. The heat exchange in this design takes place by direct contact of the waste water with the cold water conduit.

U.S. Pat. No. 4,304,292 issued to Cardone et al. on Dec. 8, 1981 discloses a shower unit in which a U-shaped conduit as part of a heat exchange apparatus. A heat exchange conduit is coiled around the exterior of the U-shaped conduit. Cold water flows through the coiled conduit and is heated by the waste water flowing through the U-shaped conduit, although there is no indication as to the nature of the contact between the coils and the U-shaped conduit. It is possible that the heat exchange is occurring across the walls of the two conduits. The coiled cold water conduit may also be located internally of the U-shaped conduit. Heat exchange appears to take place by direct contact of the waste water with the coiled cold water conduit.

U.S. Pat. No. 4,300,247 issued to Berg on Nov. 17, 1981 discloses a heat exchanger integral with the base of a shower unit in which a drain hole is in communication with the heat exchanger. The heat exchanger has a pair of so-called drain water flow through compartments, which are separated by a heat conducting material from a pair of cold water flow through compartments. Cold water is fed into the compartments and, after absorbing heat from the drain water, exits via an output. The heat exchange appears to occur by direct contact of water with the surface of a supply of cold water; in this case, however, instead of being a conduit, the cold water is located in compartments. Waste water fills one side of a number of serpentine compartments up to a line and exchanges heat across the folded layers of heat conductive material into complementary cold water containing compartments. Presumably, this folded arrangement of the heat conductive material allows for a great surface area over which the heat exchange can take place. The heat exchange takes place by direct contact of waste water on the container of cold water.

U.S. Pat. No. 6,722,421 issued to MacKelvie on Apr. 20, 2004 discloses a rather complex arrangement of either vertical or horizontal heat exchangers which have built-in heat storage for continuous heat recovery from waste drain water. A vertical heat exchanger includes a drain conduit connected to a drain water source, a water reservoir surrounding the drain conduit and a cold water conduit coiled around the water reservoir. A number of nested convection chambers are located on the external wall of the drain conduit and hold a volume of water adjacent to the wall of the drain conduit. In operation, drain water in the drain conduit heats the volume of water in the chambers, which through convention flows into the reservoir thereby heating same and the cold water flowing through the coiled conduit. The horizontal version of the heat exchanger has a convention chambers that appears to “cup” the central drain conduit and operate on the same convection principle as described for the vertical design. Interestingly, simultaneous flow of cold water in the coiled conduit and waste water in the drain conduit is not necessary. There is no contact between the drain conduit and the cold water conduit.

U.S. Pat. No. 5,791,401 issued to Nobile on Aug. 11, 1998 discloses a portion of a waste water conduit which is U-shaped. The drain conduit includes a number of axially disposed consecutive solid wall ridges and depressions, which are located around the entire inner surface of the drain conduit. A cold water conduit is coiled around the waste water conduit and includes a smooth, arcuate thermal transfer surface complementary to the curvature of the cold water conduit sidewall. This design appears to operate when the void in the U-shaped portion of the waste water drain conduit is entirely filled with waste water.

U.S. Pat. No. 5,740,857 issued to Thompson et al., Apr. 21, 1998 discloses a heat recovery and storage device useful to recover heat from warm waste water in which a generally horizontal waste water conduit is surrounded by a cold water reservoir. The waste water conduit includes a number of projections made of a high thermally conductive material located on a lower external surface of the conduit and which project into the cold water reservoir so as to transfer heat to same. The upper portion of the conduit is made of a material which limits heat re-conduction. The cold water is in direct contact with the outer wall of the drain water conduit.

U.S. Pat. No. 4,256,170 issued to Crump on Mar. 17, 1981 discloses a liquid-to-liquid heat exchanger which includes a number of fins located at a lower portion of the waste water conduit. The fins are arranged to define a generally serpentine fluid pathway within a jacket of cold water, which surrounds the waste water conduit. The fins are also used to transfer heat to the cold water and induce turbulence in the cold water flow.

Thus, there is a need for an improved heat exchange apparatus, in which the fluids do not contact each other and which provides efficient thermal energy transfer across the heat exchanger walls over a short pathway, and in which debris and maintenance tooling can pass through the heat exchange apparatus.

SUMMARY OF THE INVENTION

We have designed a novel, blade-type, passive fluid-to-fluid heat exchange apparatus, which uses turbulators to induce and maintain turbulent flow to provide unexpectedly high efficiency heat recapture from waste water (also known as “grey water”) commonly found in household shower and bath systems. Moreover, the blade members are self-supporting and do not require additional frames for support as is typically required in existing heat exchange designs.

Accordingly, in one aspect there is provided a heat exchange apparatus, the apparatus comprising: a hollow blade member having a first fluid inlet and a first fluid outlet and a first fluid passageway for a first fluid extending therebetween, the blade member being sized and shaped for location in a second fluid passageway for a second fluid, the blade member being configured to enhance thermal energy transfer between the fluids as they flow along their respective passageways.

Accordingly in another aspect, there is provided a blade heat exchange apparatus, the apparatus comprising: at least one blade member having a first fluid inlet and a first fluid outlet, and a first fluid passageway for a first fluid extending therebetween, the blade member having a longitudinal blade axis; a second fluid passageway for a second fluid, the second fluid passageway being sized and shaped to receive therein the blade member; the blade member has two blade walls, each blade wall having an inner and outer thermal transfer surface, the thermal transfer surfaces each having a plurality of spaced apart ridges and recesses, the ridges and recesses being substantially parallel to each other, the ridges and recesses of the first blade wall being angled in a first direction relative to the longitudinal axis, the ridges and recesses of the second blade wall being angled in a second direction relative to the longitudinal axis, the second direction being different from the first direction so as to induce cross flow in the first and second fluids as they travel along their respective passageways.

Accordingly in another aspect, there is provided a heat exchange apparatus, comprising: a central conduit having a conduit wall; an outer jacket substantially encasing the central conduit, the jacket being spaced apart from the conduit wall to define an enclosure and having a fluid inlet and a fluid outlet; a turbulator located in the enclosure, the turbulator having a first helical wire disposed in a clockwise orientation and a second helical wire disposed counterclockwise to the first helical wire so as to induce shear turbulent flow in a fluid as it flows through the enclosure and contacts the turbulator.

Accordingly in another aspect, there is provided a heat exchange apparatus, the apparatus comprising: a central conduit having a conduit wall; an outer jacket substantially encasing the central conduit, the jacket being spaced apart from the conduit wall to define an enclosure and having a fluid inlet and a fluid outlet; a mesh turbulator located in the enclosure, the mesh turbulator being configured to induce shear and turbulent flow in a fluid as it flows through the enclosure and contacts the turbulator.

Accordingly in one embodiment of the present invention there is provided a heat exchange apparatus, the apparatus comprising:

a) at least one hollow fin member having first and second thermal transfer surfaces, the first thermal transfer surface defining a first fluid passageway for a first fluid, which first fluid being flowable along the first passageway in contact with the first thermal transfer surface; and

b) a second fluid passageway for a second fluid, the second fluid passageway being located in intimate contact with the second thermal transfer surface, such that the first fluid when flowing along the first fluid passageway exchanges thermal energy with the second fluid flowing along the second fluid passageway.

Accordingly in another embodiment of the present invention there is provided a heat exchange apparatus, the apparatus comprising:

a) a channel member having first and second end portions, the channel member having a plurality of hollow fin members extending between the first and second end portions, the fin members having first and second thermal transfer surfaces, the first thermal transfer surface defining a first fluid passageway, the first end portion being connectable to a source of a first fluid, the first fluid entering the first end portion at a first temperature and flowable along the first thermal transfer surface, the first fluid exiting the second end portion at a second temperature; and

b) a second fluid passageway having an inlet and an outlet, the second fluid passageway being located in intimate contact with the second thermal transfer surface, the inlet being connectable to a source of a second fluid, the second fluid entering the inlet at a third temperature and flowable along the second fluid passageway, such that the first fluid when flowing along the first fluid passageway exchanges thermal energy with the second fluid flowing along the second fluid passageway, the second fluid exiting the outlet at a fourth temperature.

Accordingly in one embodiment of the present invention there is provided a heat exchange apparatus, the apparatus comprising:

a) a channel member having first and second thermal transfer surfaces, at least one thermal transfer surface being uneven and defining a first fluid passageway for a first fluid; and

b) a second fluid passageway for a second fluid, the second fluid passageway being located in intimate contact with the second thermal transfer surface, the flow of at least one of the fluids being disrupted such that the first fluid when flowing along the first fluid passageway exchanges thermal energy with the second fluid flowing along the second fluid passageway.

Accordingly in another embodiment of the present invention, there is provided a heat exchange apparatus, the apparatus comprising:

a) a fluid passageway having a fluid passageway sidewall of a membraneous material, the material having at least one heat conductive surface locatable in intimate contact with a portion of a conduit sidewall, the conduit having an inlet and an outlet, a first fluid entering the inlet at a first temperature and exiting the outlet at a second temperature, the fluid passageway sidewall being spreadable over an area of the conduit sidewall, the fluid passageway having a fluid passageway inlet and a fluid passageway outlet, a second fluid entering the fluid passageway inlet at a third temperature and exiting the fluid passageway outlet at a fourth temperature.

Accordingly, in another embodiment, there is provided a heat exchange apparatus, the apparatus comprising:

a) a conduit having an arcuate conduit member having first and second ends, and an arcuate heat exchanger having first and second connecting portions sealingly connectable to the respective first and second ends, the heat exchanger having first and second thermal transfer surfaces, an amount of a first fluid entering the conduit at a first temperature and being in contact with the first thermal transfer surface and exiting the conduit at a second temperature; and

b) a fluid passageway having a fluid passageway sidewall of a membraneous material, the material having at least one heat conductive surface locatable in intimate contact with the second thermal transfer surface, the fluid passageway sidewall being spreadable over an area of the second thermal transfer surface, the fluid passageway having a fluid passageway inlet and a fluid passageway outlet, a second fluid entering the fluid passageway inlet at a third temperature and exiting the fluid passageway outlet at a fourth temperature.

Accordingly in another embodiment of the present invention, there is provided a heat exchange apparatus for use with a P-Trap having an inlet and an outlet, the P-Trap having a first drain portion disposed orthogonal to the ground and connectable to a drain, a second drain portion being disposed away from the ground in a downward gradient, and a U-shaped drain portion interconnecting the first and second drain portions, the apparatus comprising:

a) a fluid passageway having a fluid passageway sidewall of a membraneous material, the material having at least one heat conductive surface locatable in intimate contact with a sidewall of first drain portion, the second drain portion and the U-shaped portion, a first fluid entering the inlet at a first temperature and exiting the outlet at a second temperature, the fluid passageway sidewall being spreadable over an area of the first drain portion, the second drain portion and the U-shaped portion sidewall, the fluid passageway having a fluid passageway inlet and a fluid passageway outlet, a second fluid entering the fluid passageway inlet at a third temperature and exiting the fluid passageway outlet at a fourth temperature.

Accordingly in another embodiment of the present invention, there is provided a drainage apparatus for use with a drain trap, the apparatus comprising:

a) a P-Trap having an inlet and an outlet, the P-Trap having a first drain portion being disposed orthogonal to the ground and connectable to the drain trap, a second drain portion being disposed away from the ground in a downward gradient and a U-shaped drain portion interconnecting the first and second drain portions;

b) the second drain portion comprising:

-   -   i) an arcuate conduit member having first and second ends, and         an arcuate heat exchanger having first and second connecting         portions sealingly connectable to the respective first and         second ends, the heat exchanger having first and second thermal         transfer surfaces, an amount of a first fluid entering the         second drain portion at a first temperature and being in contact         with the first thermal transfer surface and exiting the second         drain portion at a second temperature; and     -   ii) a fluid passageway having a fluid passageway sidewall of a         membraneous material, the material having at least one heat         conductive surface locatable in intimate contact with the second         thermal transfer surface, the fluid passageway sidewall being         spreadable over an area of the second thermal transfer surface,         the fluid passageway having a fluid passageway inlet and a fluid         passageway outlet, a second fluid entering the fluid passageway         inlet at a third temperature and exiting the fluid passageway         outlet at a fourth temperature.

Accordingly in another embodiment of the present invention, there is provided a drainage apparatus for use with a drain trap, the apparatus comprising:

a) a P-Trap having a drain portion disposed orthogonal to the ground and connectable to the drain trap and a U-shaped drain portion;

b) a heat exchanger in fluid communication with the U-shaped portion, the heat exchanger having a channel member having first and second end portions, the channel member having a plurality of hollow fin members extending between the first and second end portions, the fin members having first and second thermal transfer surfaces, the first thermal transfer surface defining a first fluid passageway, a first fluid entering the first end portion from the U-shaped portion at a first temperature and flowable along the first thermal transfer surface, the first fluid exiting the second end portion at a second temperature; and

c) a second fluid passageway having an inlet and an outlet, the second fluid passageway being located in intimate contact with the second thermal transfer surface, the inlet being connectable to a source of a second fluid, the second fluid entering the inlet at a third temperature and flowable along the second fluid passageway, such that the first fluid when flowing along the first fluid passageway exchanges thermal energy with the second fluid flowing along the second fluid passageway, the second fluid exiting the outlet at a fourth temperature.

Accordingly in one embodiment of the present invention there is provided a drainage apparatus for use with a drain trap, the apparatus comprising:

a) a P-Trap having a drain portion being disposed orthogonal to the ground and connectable to the drain trap and a U-shaped drain portion;

b) a heat exchange apparatus in fluid communication with the U-shaped portion, the apparatus having a channel member having first and second thermal transfer surfaces, at least one thermal transfer surface being uneven and defining a first fluid passageway for a first fluid received from the U-shaped portion; and

c) a second fluid passageway for a second fluid, the second fluid passageway being located in intimate contact with the second thermal transfer surface, the flow of at least one of the fluids being disrupted such that the first fluid when flowing along the first fluid passageway exchanges thermal energy with the second fluid flowing along the second fluid passageway.

Accordingly, in another embodiment there is provided a heat exchange apparatus, as described in the embodiments above, for use with a drain trap of a bath tub or a shower tub in a household drainage system.

Accordingly, in another embodiment there is provided a turbulator for inducing turbulent flow in a fluid, the turbulator comprising: a hollow blade member having a fluid inlet and a fluid outlet, and a fluid passageway for the fluid extending therebetween, the fluid passageway being configured to induce turbulent flow in the fluid as it flows therealong.

Accordingly, in yet another embodiment, there is provided a heat exchange apparatus, the apparatus comprising: a plurality of turbulators for inducing turbulent flow in a first fluid, each turbulator having a hollow blade member having a fluid inlet and a fluid outlet, and a first fluid passageway for the first fluid extending therebetween, the first fluid passageway being configured to induce turbulent flow in the first fluid as it flows therealong; and a second fluid passageway for a second fluid, the second fluid passageway being sized and shaped to receive the turbulators therein and configured to induce turbulent flow in the second fluid as it flows along the second fluid passageway.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings wherein:

FIGS. 1A and 1B illustrate a household shower/bath system showing the location of an embodiment of a heat exchange apparatus;

FIG. 2 is an exploded perspective view of an embodiment of a heat exchange apparatus;

FIG. 3A is a perspective view of a channel member of FIG. 2;

FIG. 3B is a partial cross-sectional view taken along line 3 b-3 b′ of FIG. 3 showing two uneven thermal transfer surfaces;

FIG. 4A is an end view of the channel member showing a single uneven thermal transfer surface;

FIG. 4B is a detailed view of a number of peaks and troughs of the channel member of FIG. 4A;

FIG. 5A is a longitudinal cross section view of the heat exchange apparatus showing the location of end caps;

FIGS. 5B and 5C are end views showing respectively the first end cap and the second end cap located relative to the channel member;

FIG. 5D is a cross sectional end view of the heat exchange apparatus with the end cap removed;

FIG. 6 is a perspective view of another embodiment of a capillary heat exchange apparatus with end caps removed to show a channel member;

FIGS. 7A-7D are a number of cross section views of the channel member of FIG. 6 showing different locations of capillaries and double walls;

FIG. 8 is an alternative cross section view of the channel member of FIG. 6 showing the location of grey water;

FIGS. 9A and 9B are diagrammatic representations showing an end view comparison of a standard conduit with a heat exchange apparatus;

FIG. 10 is a detailed partially exploded perspective view of an alternative capillary embodiment of a heat exchange apparatus;

FIG. 11 is a partial cutaway view showing detail of the apparatus of FIG. 10;

FIGS. 12A and 12B are respectively an end view and a perspective view of an insert showing circumferentially disposed hollow (capillary) fin members;

FIG. 13 is a longitudinal cross sectional view of an embodiment of a partial clam shell and partial blister pack heat exchange apparatus located around a grey water pipe;

FIG. 14 is a cross sectional end view of a blister pack-type heat exchange apparatus located adjacent a grey water pipe;

FIGS. 15A and 15B are cross sectional views showing a double wall bladder-type heat exchange apparatus and a blister pack heat exchange apparatus located around a grey water pipe;

FIG. 16 is a cross sectional end view of an embodiment of a heat exchange apparatus showing an arcuate insert and atmospheric vent;

FIGS. 17A and 17B illustrate a household shower/bath system showing the location of a heat exchange apparatus relative to a P-Trap;

FIGS. 18A and 18B illustrate a household shower/bath system showing the location of a check valve relative to the heat exchange apparatus;

FIGS. 19A and 19B is an end view and a perspective partial exploded view of an alternative embodiment of a heat exchange apparatus showing a one piece insert having a multiple fluid circuit;

FIG. 20A is a perspective partial exploded view of a heat exchange apparatus showing multiple one piece inserts;

FIG. 20B is an end view of the heat exchange apparatus of FIG. 20A;

FIG. 21A is a perspective exploded view of an embodiment of an alternative capillary heat exchange apparatus;

FIG. 21B is a side view of the heat exchange apparatus of FIG. 21A

FIG. 21C is a cross sectional view of the channel member of FIG. 21A showing square top hollow fin members;

FIG. 22A is an end view of round top capillary heat exchange walls;

FIG. 22B is diagrammatic representation of a heat exchange apparatus showing difference planes of flow for grey water;

FIG. 23 is a perspective view of an embodiment of a blade type heat exchange apparatus with blade members removed;

FIG. 24A is a perspective view of an alternative embodiment of a blade type heat exchange apparatus showing blades having surface patterns;

FIG. 24B is a partial cross-sectional view of blade members of FIG. 24A showing interdigitating surface projections;

FIG. 25A is a diagrammatic representation of a hollow blade member showing combined performance enhancement surface features in which GW is grey water and CW is cold water;

FIG. 25B is a diagrammatic representation of the hollow blade member taken along lines 25B showing fluid flow patterns;

FIG. 26 is a perspective, exploded view of an alternative embodiment of a blade type heat exchange showing blades having angled surface ridges;

FIG. 27 illustrates a number of club grip type corrugated heat exchanger piping;

FIG. 28A is a side view of a blade member showing in solid lines a plurality of angled ridges on one surface and in phantom lines a plurality of angled ridges on another surface and illustrating criss cross patterns and contact points;

FIG. 28B is a cross sectional view of the blade member taken along line 28B showing the location of ridges and recesses of two blade surfaces;

FIG. 29 is a diagrammatic representation of a section of a blade member showing a centre spot weld, ridges, and crimped ends;

FIG. 30A is a longitudinal cross section view of a double wall blade member showing atmospheric vents;

FIG. 30B is a cross section view of the blade member taken along 30B showing the double wall and surface textures;

FIG. 31A is a diagrammatic representation of a hollow blade member showing macroscopic and microscopic textures and fluid flow patterns;

FIGS. 32A and B is a representation of a golf ball showing alternative icosahedron dimple structure;

FIG. 33 is a perspective partial cutaway view of a blade-type heat exchanger;

FIG. 34 is a detailed view of an end portion of the blade-type heat exchanger of FIG. 33 showing the manifold and heat exchange wall details;

FIG. 35 is a detailed side view of one end of the heat exchange apparatus of FIG. 33 showing ridges and recesses of blade member surfaces;

FIG. 36 is a partially exploded view of a blade type heat exchanger showing an alternative orientation of the cold water manifolds;

FIG. 37 is a perspective view of a large scale blade-type heat exchange apparatus housing;

FIG. 38 is a perspective view of the heat exchange apparatus of FIG. 3 with the top removed to show the blade members;

FIG. 39 is a side view of a large dimensioned blade member;

FIG. 40 is a perspective view of an alternative design of a large dimension heat exchanger apparatus housing;

FIG. 41 is a side view of an alternative embodiment of a vertical heat exchange apparatus;

FIG. 42 is a longitudinal cross sectional view of the heat exchange apparatus of FIG. 41 showing the location of a double slinky turbulator;

FIG. 43 is a detailed view of a section of the double slinky wire turbulator;

FIGS. 44A and 44B are respectively a partial cutaway view and a detailed view of a double slinky wire turbulator;

FIGS. 45A, 45B and 45C are respectively a partial cutaway view and a detailed views of a mesh turbulator;

FIGS. 46A-46H illustrate a number of designs of compact heat exchanger apparatus comprising internally located wire turbulators or surface defined ribbed turbulators;

FIGS. 47A and 47B are perspective view of respectively a smooth turbulator and a double sided ribbed turbulator;

FIG. 48 is a diagrammatic representation of a system for controlling and for monitoring heat exchange apparatuses.

DETAILED DESCRIPTION Definitions

Unless otherwise specified, the following definitions apply:

The singular forms “a”, “an” and “the” include corresponding plural references unless the context clearly dictates otherwise.

As used herein, the term “comprising” is intended to mean that the list of elements following the word “comprising” are required or mandatory but that other elements are optional and may or may not be present.

As used herein, the term “consisting of” is intended to mean including and limited to whatever follows the phrase “consisting of”. Thus the phrase “consisting of” indicates that the listed elements are required or mandatory and that no other elements may be present.

As used herein, the term “turbulator” when referring to either a surface or to an insert having a surface that acts as a turbulator, is intended to mean that the surface has a plurality of projections extending away therefrom. Surface turbulators and inserted turbulators are used to increase convenction rates and heat transfer coefficients at heat exchange surfaces in fluid passageways in order to provide high performance in compact heat exchange assemblies, and to orientate fluids into a pre-defined direction often resulting in chaotic paths. Examples of types of turbulators include, but are not limited to, corrugations, peaks and troughs, nubbins, raised chevrons having a gap between, fish scales, raised zigzag moldings, meshes, criss cross oriented wires, porous materials, and the like. Turbulators may comprise uniform or non-uniform surface profiles, textures, open cell structures, and shapes. Porosity and fluid passageway geometry allow control of fluid flow via solid or semi-solid mechanical structures and may be constructed from laminate composites, molded parts, and even mesh of plastics, ceramics, metals or other materials.

As used herein the term “fluid” is intended to mean gas or liquid. Examples of liquids suitable for use with the heat exchangers described herein include, but are not limited to, water, hydraulic fluid, petroleum, glycol, oil and the like. Examples of gases include, for example, combustion engine exhaust gases and steam.

The invention features a novel heat exchange apparatus in which hollow fin members or hollow blade members with or without surface patterns can be used to promote efficient thermal energy transfer between fluids across thermal energy transfer surfaces. The flow of fluids can be passive, i.e. by gravity or can flow under the influence of pressure, either above or below atmospheric pressure. The heat exchange apparatuses described herein are also self-draining. Moreover due to their design, the blade members can be located directly in a grey water pathway with or without the use of pre-filtration to remove particulate debris. In one example, the efficiency of heat recapture is 40-60% when compared to 25% heat recapture efficiency of conventional systems. To achieve this, in one example, we use a channel with plurality of hollow blades to move, by gravity, grey water along a pathway such that it exchanges its heat (typically about 40° C.) to a source of cold water flowing through another passageway located in intimate contact with the channel. In other examples, higher fluid temperatures (>100° C.) can also exchange their thermal energy to cold water so as to generate steam. The heat exchange takes place across a thin (typically from about 1/1000 inch to about ⅕ inch thickness) double wall arrangement. Furthermore, thermal energy transfer occurs along a significantly shorter pathway between thermal transfer surfaces when compared to thermal transfer across solid fins. The cold water is heated to produce warmed water, which may then be stored in a storage tank or communicated to a mixing valve in a shower or bath system. Advantageously, the heat exchanger apparatus is constructed from inexpensive materials and when installed is essentially maintenance-free. The grey water conduits (pipes) used are standard 1.5 to 4 inch and are universally retrofittable into existing plumbing systems with the minimum of disruption to the household. The apparatus may also be connectable to active heat exchange apparatus such as, for example, a Peltier Module. The various designs of heat exchange apparatus will now be described in detail.

Referring now to FIGS. 1A and 1B, an embodiment of a modular heat exchange apparatus is shown generally at 10 in use with a household shower and bath system 12. The household shower and bath system 12 includes a water heater 14, a hot water line 16, a cold water line 18, a warm water line 20, a mixing valve 22, a shower head 24 and a drain trap 26. The hot and warm water lines 16, 20 are each connected to the mixing valve 22, the temperature of the water exiting the shower head 24 being controlled by the user operating the mixing valve 22. The cold water line 18 is connected to the heat exchange apparatus 10 and feeds cold water 25 (a second fluid) into the apparatus 10. The warm water line 20 is connected to the heat exchange apparatus 10 and the mixing valve 22. The drain trap 26 receives drain water 28 (so called “grey water”) (a first fluid) from the shower/bath tub and communicates the drain water to the heat exchange apparatus 10. After flowing through the heat exchange apparatus 10, the grey water 28 exits the household shower system 12 to a main drain (not shown). It should be noted that although an example of a household shower/bath system is illustrated, the heat exchange apparatus described may also be used for other applications that require heat exchange between two fluids. Furthermore, it is to be noted that any of the heat exchangers described hereinbelow can also be connected to the system 12.

Referring now to FIG. 2, the heat exchange apparatus 10 is described in more detail. Broadly speaking, the heat exchange apparatus 10 comprises a channel member 30 which has a first end portion 32 and a second end portion 34, and which defines a first fluid passageway 36 for the first fluid 28. The channel member 30 includes a first thermal transfer surface 38 and a second thermal transfer surface 40. At least one of the thermal transfer surfaces is uneven. In the example illustrated, both the thermal transfer surfaces 38, 40 are uneven. In the example shown, the first thermal transfer surface 38 is corrugated and defines a plurality of fin-like peaks (or blades) 42 and troughs 44 that extend longitudinally along the channel member 30 between the first and second end portions 32, 34. Although the peaks 42 and troughs 44 are disposed substantially parallel to each other, it is to be understood that the peaks 42 and troughs 44 can be arranged in any manner. The first end portion 32 is connectable to a source of the grey water 28, which enters the first end portion 32 at a first temperature T1 and flows along the surface 38, exiting the second end portion 34 at a second temperature T2. A second fluid passageway 46, typically a cold water conduit, has a second fluid inlet 48 and a second fluid in outlet 50, and is located in intimate contact with the second thermal transfer surface 40 of the channel member 30. The second fluid inlet 48 is connectable to a source of the second fluid (not shown), which enters the inlet 48 at a third temperature T3 and flows along the second fluid passageway 46. The grey water 28 exchanges thermal energy with the cold water such that it exits the outlet 50 at a fourth temperature T4 as warmed water. The temperature of the warmed water T4 is greater than the temperature T3 of the cold water entering the inlet 48. The warmed water feeds into the warm water line 20 and may be mixed with hot water in the mixing valve 22.

The first and second fluids flow in a contra-flow manner through the heat exchange apparatus 10. It is also possible to have the fluids flow in a parallel flow manner. The first temperature T1 of the first fluid 28 entering the first fluid passageway 36 can be greater than or less than the second temperature T2 of the first fluid 28 as it exits the first fluid passageway 36. Similarly, the third temperature T3 of the second fluid 25 can be greater than or less than the fourth temperature T4 of the second fluid 25 as it exits the second passageway 46. In the examples illustrated herein, the first temperature T1 of the first fluid 28 entering the first fluid passageway 36 is greater than the second temperature T2 of the first fluid 28 as it exits the first fluid passageway 36. The third temperature T3 of the second fluid 25 is less than the fourth temperature T4 of the second fluid 25 as it exits the second fluid passageway 46. By way of example, T1 is typically 40° C. for grey water (the first fluid), T2 is typically 30° C. for grey water exiting the heat exchanger 10, T3 is typically 10° C. for cold water (the second fluid), and T4 is typically 24° C. for warmed water entering the warm water line 22 from the heat exchanger 10. To measure the efficiency of the heat exchange apparatus, the following equation is used:

${Effectiveness} = \frac{T_{{cold}\mspace{14mu} {out}} - T_{{cold}\mspace{14mu} i\; n}}{T_{{grey}\mspace{14mu} i\; n} - T_{{cold}\mspace{14mu} i\; n}}$

where T denotes temperature in ° C.

At least one of the fluids flows through its respective passageway under pressure, the other fluid flowing through its respective passageway at atmospheric pressure. Typically, the second fluid (the cold water) flows under pressure at approximately 50 psi along the second fluid passageway 46.

Still referring to FIG. 2, the heat exchange apparatus 10 further comprises an arcuate piece 52, a first end cap 54 and a second end cap 56. A support member 58 interconnects the arcuate piece 52, the end caps 54, 56, and provides a housing for the channel member 30 and the second fluid passageway 46. The channel member 30 may optionally include a mesh filter 60 which lies snug against the channel member 30. The mesh filter 60 significantly reduces the amount of debris, such as hair, soap scum and other particulates, which would otherwise clog the channel member 30.

Referring now to FIGS. 3A and 3B, the channel member 30 is generally elongate and, when viewed in cross-section, is H-shaped. The channel member 30 includes two sidewalls 62, 64 which form a boundary on either side of the channel member 30. It is to be understood that although the channel member 30 in this example illustrated is H-shaped, any cross sectional shape is possible. When connected to the drain trap 26, the channel member 30 is disposed away from a horizontal plane towards the ground at an angle of about 1° such that when the grey water from the shower drain enters the channel member 30 at the first end portion 32 it flows passively and by gravity along the first fluid passageway towards the second end portion 34. Two adjacent peaks 42 a and 42 b define one trough 44 a located therebetween. A fluid convection promoter 68 (or turbulator) is located at a trough base 70 and projects into the trough 44 a. The convection promoter 68 is located on the first thermal transfer surface 38 and increases thermal exchange, across the surface 38. Located between an end peak 42 c and each side wall 62, 64 is another convection promoter 68. The convection promoters 68 can be in the form of a microscopic peak, although other promoters known to those skilled in the art can be used. The second thermal transfer surface 40 may optionally include a plurality of fin-like projections (or blades) 66, which extend away from the surface 40, as best illustrated in FIG. 3B. In one example, the projections 66 may be also be corrugations similar in shape to the corrugations on the first thermal transfer surface 38. The cold water conduit (the second fluid passageway) lies snugly and in intimate contact with the projections 66 so as to provide highly efficient heat transfer from the first fluid passageway 36 to the second fluid passageway 46.

Referring now to FIGS. 4A and 4B, the second thermal transfer surface 40 is smooth. In this case, the second fluid passageway 46 is located adjacent the second thermal transfer surface 40 and includes a plurality of turbulators 72 located in the second fluid passageway 46. The turbulators 72 in due turbulence and establish shear forces in the second fluid as it flows through the second fluid passageway 46. A number of turbulators designed for round pipe insertion are known to those skilled in the art.

As best illustrated in FIG. 4B, as the grey water flows along the first fluid passageway 36 a rotational flow pattern is established, as indicated by the arrows, between adjacent peaks. This convective rotational flow pattern provides enhanced transfer of thermal energy from the grey water to the heat conductive peaks 42 and troughs 44 of the first thermal transfer surface 38 to the second fluid passageway 46 located adjacent thereto. Delaminators (turbulators) can also be used to induce fluid rotation, or laminar flow disrupters (turbulators) may be used to enhance thermal energy transfers and also to manage fluid flow. Advantageously, turbulators also manage debris and reduce its accumulation in the first and second fluid passageways.

As best illustrated in FIGS. 2 and 5A through 5D, the first end cap 54 is connected to the first end portion 32 of the channel member 30, whereas the second end cap 56 is connected to the second end portion 34. In order to aid flow of the grey water along the first fluid passageway 36 by gravity and to reduce “pooling” of water in the apparatus, the second end cap 56 is disposed at an angle away from a longitudinal axis 74 of the channel member 30. The location of the second end cap 56 with respect to the first end cap 54 creates a deviation away from the axis 74. While this may be acceptable to some local plumbing regulations, it may be prohibited in others. In order to circumvent this problem, the first end cap 54 can be connected to the lower first end portion of the channel member 30 with the same deviation from the longitudinal axis of the channel member 30 such that the grey water would flow along the channel member at a typical angle of 1° away from the horizontal.

Referring now to FIG. 6, an alternative example of a heat exchange apparatus 76 is illustrated which comprises a non-H shaped channel member 78, the first and second end caps 54, 56, the cold water inlet 48 and the warmed water outlet 50. The channel member 78 includes a plurality of capillary hollow fin members 79 which define wave-like peaks 80 and troughs 82 extending along the channel member 78 between the first and second end portions 32, 34.

As best illustrated in FIGS. 7A through 7D, the hollow fin members 79 include a first thermal transfer surface 84 located on an upper portion of a first wall 86 (adjacent the grey water), the first thermal transfer surface 84 defining the first fluid passageway 28 for the first fluid, and a second wall 88 located in intimate contact with the first wall 86. A second thermal transfer surface 90 is located on a lower portion of the second wall 88. The grey water flows along the first fluid passageway 28 in contact with the first thermal transfer surface 84. A second fluid passageway 92 is in intimate contact with the second thermal transfer surface 90. The second fluid passageway 92 is a capillary which carries the second fluid. The walls 86, 88 are generally constructed from thin sheet thermally conductive material such as, for example, aluminium, gold, copper or alloys thereof. Additionally, the second wall 88 is sandwiched between the capillary fluid passageway 92 and can allow venting to the atmosphere via an interstitial gap between the first and second walls 86, 88 in the event that the integrity of the walls 86, 88 are compromised. It should be noted that although a double wall arrangement is illustrated, a single wall arrangement is also contemplated, such that the capillary lies in intimate contact with the second thermal transfer surface of the single wall. The channel member 78 is mounted on a support 94 that includes a number of complementary posts 96 which extend into the space between adjacent peaks. As described above for the heat exchange apparatus 10, the grey water flows along the first fluid passageway it exchanges thermal energy with the cold water flowing along the second fluid passageway. However, in this case the hollow design of the fin members 79 allows heat exchange across a thin (typically from about 1/1000 inch to about ⅕ inch thickness) wall arrangement, such that thermal energy transfer occurs along a significantly shorter pathway between the thermal transfer surfaces when compared to thermal transfer across solid fins as described above. The thin walls of the heat exchanger 76 improve performance. Various stiffeners such as, for example, surface adhesion, interlocking geometries, external supports, fasteners, internal ribs and chambers, as well as turbulators or combinations thereof, are used to allow the use of thin walls. Water hammer protection (not shown) can be built into the soft zones of the support 94 or the posts 96. Additionally, turbulators (surface or insertable) may be used with either of the first and second fluid passageways.

As best illustrated in FIG. 8, instead of having a capillary fluid passageway 92 for the second fluid, the second fluid may flow against the lower portion of the second wall 88 with the addition of turbulators 98 to provide forced convection by shearing of the second fluid at it travels in intimate contact with the second thermal transfer surface. It is also possible to have similar turbulators 98 on the first thermal transfer surface, but this may compromise the flow of the grey water. An additional advantage of having turbulators 98 replacing posts 96 is increased strengthening of the channel member. Owing to the thinness of the walls of the hollow fin members, strengthening members such as the turbulators 98 may be necessary to maintain the structural integrity of the channel member. Grey water flowing along the channel member 78 fills the troughs 82 to near the top of the peaks 80. Thermal energy is transferred across the first thermal transfer surface 84 to the second thermal transfer surface 90 via the first and second walls 86, 88 and to the cold water flowing in the second fluid passageway 92.

Referring now to FIGS. 9A and 9B, typically, grey water exiting the drain trap 26 of the shower or bath tub enters a cylindrical 2-inch drain pipe 70 and defines a surface areas of approximately 0.85 in² at a flow rate of approximately 10 L/minute. A volume of the grey water in the pipe 70 normally never contacts the sidewall of the pipe 70 and if thermal energy is to be recaptured by heat exchange across the sidewall, its transfer will be largely inefficient. Advantageously, using the channel members 30 and 78 described above, the grey water 8 flows along the first fluid passageway 36 at the same flow rate as with the pipe 70, but does so over the length of the channels by contacting the heat conductive peaks 42 and troughs 44. Thus, the distribution of the 0.85 in² area into multiple smaller area sections maximizes the heat transfer from the grey water by maximizing heat exchange contact area surfaces.

Referring now to FIGS. 10, 11, 12A and 12B, in which an alternative embodiment of a heat exchange apparatus is illustrated generally at 100. The apparatus 100 comprises a circumferentially disposed channel member 102, two end manifolds 104, 106, optional turbulators 108, and an outer sleeve 109. The channel member 102 includes a plurality of hollow fin members 110 and a capillary cold water passageway 112, which lies in intimate contact with the second thermal transfer surface. A cold water inlet 114 feeds cold water into the capillary 112 and warmed water exits the capillary at an outlet 116. Grey water flows into the apparatus 100 via the manifold 104 and flows over the first thermal transfer surface of the channel member 102. The turbulators 108 not only disrupt the flow of the grey water and create forced convention, but they also maintain the structural integrity of the hollow fin members 110. The turbulators can be surface turbulators or insertable turbulators. Water hammer protection (not shown) can be built into the soft zones of the turbulators 108. A one-piece capillary insert 111, as illustrated in FIGS. 12A and 12B, may be inserted into the outer sleeve 109. The one-piece insert 111 includes the channel member 102 as described above. The turbulators 108 can also be inserted into the insert 111 to further enhance thermal transfer as well as enhance the structural integrity of the apparatus. The centrally disposed turbulator 108 can be used in a configuration where the shaft of the element 108 is used to fasten and tighten the manifolds 104, 106.

Referring now to FIG. 13, an alternative embodiment of a heat exchange apparatus of the present invention is shown generally at 200. Broadly speaking, the heat exchange apparatus 200 comprises a cold water fluid passageway 202, which has an optional fluid passageway sidewall 204 in double wall configurations that is made of a membraneous material, which is pliable, yet resilient. The material can be made from pliable sheet material, such as, for example, but not limited to, gold, copper, or aluminium. The material includes at least one heat conductive surface 206 which is located in intimate contact with a portion of a sidewall 208 of a grey water conduit 210. The conduit 210 has an inlet 212 and an outlet 214. The grey water enters the inlet 212 at a first temperature T1 and exits the outlet 214 at a second temperature T2. In this embodiment, the fluid passageway sidewall 204 is spreadable over an area of the conduit sidewall 208. The membrane may be a single sheet of pliable material or it may be part of a bladder that is made of the same pliable material. The fluid passageway 202 may be defined by the use of an inwardly directed force from an external shell 218 that is located adjacent the sidewall 204. In the example illustrated, the shell 218 surrounds the conduit 210 and the sidewall 204. It is also contemplated that only a half shell located adjacent a lower portion of the conduit could be used. The shell 218 includes a plurality of inwardly directed projections 220, which when pressed against the membrane or bladder defines the fluid passageway 202, and act as turbulators. The fluid passageway includes a fluid passageway inlet 221 and a fluid passageway outlet 223. The second fluid (cold water) enters the fluid passageway inlet 221 at a third temperature and exits the fluid passageway outlet 223 at a fourth temperature. Examples of shells include, but are not limited to, clamshells or blister packs. The pre-defined designs of the projections 220 can be used to imprint a complementary design onto the membrane or bladder thereby define a fluid passageway having an identical design as the clamshell or blister pack. In single wall configurations, the bladder or the blister packs are omitted, and the passageway 202 is defined directly by the shell 218.

Referring to FIG. 14, an example of a blister pack type of shell 222 is shown located adjacent a heat conductive sidewall 224 of a grey water conduit 225. The blister pack 222 includes a thermal transfer surface 226 which lies in intimate contact with the conduit 225. Although the example illustrated shows a grey water conduits it is to be understood that this is an optional feature and that the grey water may flow in direct contact with the thermal transfer surface 226. A plurality of spaces 228 between adjacent blisters 230 serves as the second fluid passageway for cold water to flow therealong. One or more of the spaces 228 may also comprise turbulators. The blister pack and clam shells can be positioned so that metallic surfaces in contact with the grey water conduit effectively extend with fin-like patterns into the cold water passageway.

Referring now to FIGS. 15A and 15B, the heat exchange apparatus 200 and the blister pack 222 can be located around a grey water conduit. In the examples illustrated, the conduit includes inwardly projecting square-shaped fins 232 and an outer shell 234, which provides support for the components of the heat exchange apparatus. In one example, the bladder 204 lies snug against the outer wall of the conduit. In another example, the blister pack 222 lies in intimate contact with the sidewall 224. The blister pack 222 also defines the second fluid passageway. A drain hole 236 is located in the shell 234 to provide venting of the first and second fluid passageways away from the apparatus should either of the blister pack or the bladder rupture.

Referring now to FIG. 16, an embodiment of a heat exchange apparatus is shown generally illustrated at 300 in cross sectional view. This heat exchange apparatus 300 comprises a conduit 302 with an arcuate conduit member 304 and a fluid passageway 306. The conduit 302 has first and second ends 308, 310, and an arcuate heat exchange plate 312. The arcuate heat exchange plate 312 has first and second connecting portions 313, 314 that are sealingly connected to the respective first and second ends 308, 310 of the conduit 302. The heat exchange plate 312 has first and second thermal transfer surfaces 316, 318. An amount of grey water enters the conduit 302 at a first temperature and contacts the first thermal transfer surface 316 and exits the conduit 302 at a second temperature. Generally speaking, this embodiment is useful for grey water that covers the arcuate heat exchange plate 312 and reaches a depth of several millimeters in the conduit 302. A fluid passageway 320 similar to the one described for the heat exchange apparatus 200 above can be used with this embodiment. In this example, the fluid passageway 320 is in the form of a bladder and is located in intimate contact with the second thermal transfer surface 318 of the heat exchange plate 312. A cap 322, which is comparable to the shell described above, may be located snug against the bladder so as to form the fluid passageway 320. A drain hole 324 is located in the cap 322 to drain water away to atmosphere in case the integrity of the bladder or the conduit 302 is compromised. The ability to vent cold or grey water is a requirement for certain plumbing standards to prevent mixing of cold water with waste drain water.

Referring now to FIGS. 17A, 17B, 18A and 18B, a household shower system is shown generally at 400 and includes a P-Trap 402. P-Traps are know to those skilled in the art. The heat exchange apparatus 300 as described above, would be ideally suited for use with any part of the P-Trap such that the heat conductive surface of the heat exchange apparatus could be located in intimate contact with a sidewall of the P-trap 402. Furthermore, any part of the P-trap could be modified to include the heat exchange apparatus 300, as described above. In this case, the grey water exiting the P-Trap would contact and flow along and against the heat exchanger plate 312. Similarly, the heat exchange apparatus 10 and 76 could be used in place of downstream portions of the P-trap. The heat exchangers as described above and below may optionally include a check valve 403. The check valve 403 is of the type known to those skilled in the art. In the event of either a plumbing system failure or maintenance, simultaneous to a grey water channel wall failure of the heat exchanger, the check valve 403 will replace or supplement the double wall membrane of the heat exchanger to protect the water supply circuit of the building where the installation is located.

As best illustrated in FIGS. 19A, 19B, 20A, 20B and 21, an alternative embodiment of a heat exchange apparatus is illustrated generally at 500. The heat exchange apparatus 500 comprises a one piece insert 502 similar to the one piece insert 111 described above. In this embodiment, however, the insert 502 includes a multiple circuit 504 with a circumferentially disposed channel member 506 located inside a shell 508. The shell 508 is larger than the radius of the insert 502 and defines a void 510. The void 510 may be filled with an insulating media such as air or some other suitable insulating material. The void 510 may also contain a fluid to which the insert 502 can exchange thermal energy. The channel member 506 includes hollow capillary fin members 512, each adjacent fin member 512 having located therebetween a post 514. The insert 502 may include longitudinally disposed perforations 516, which expose the fin members 512 to fluid circulating within the shell 508. The shell 508 protects and structurally reinforces the fin members 512 either by mechanical contact or by additional components such as turbulator 526 located between the insert 502 and the shell 508. Two end caps 520 are located at either end of the insert 502 and seal the insert 502, the fin members 512 and the void 510 in the shell 508. Tubing 522 and 524 carry the grey water and cold water via manifolds (not shown) into and out of the heat exchange apparatus 500. It is to be noted that either of the tubes 522 and 524 can be individually connected in series or in parallel into one of the multiple circuits 504 as well as in contra flow or parallel directions so as to obtain the desired contra flow or parallel flow thermal performance characteristics of the heat exchange apparatus 500. Additional turbulators 526, as described above, are located between the insert 502 and the shell 508. The turbulators 526 create turbulence in all fluid passing through the void 510 and promote heat exchange on the fin members 512 through the perforations 516. Furthermore, the turbulators 526 also provide additional stiffening to the heat exchange apparatus 500.

As best illustrated in FIGS. 20A and 20B, a plurality of inserts 502 may be grouped together into a larger heat exchange apparatus 528. This heat exchange apparatus 528 is typically used when high volume, high flow and high performance is required such as for example in industrial applications. Typically, for these applications rapid heating and cooling is necessary for technical reasons, whether in grey water, pharmaceutical processes, steam generation applications, food sterilization, or cleaning applications such as in farming. Using the apparatus 528, rapid and precise heat transfer from one fluid to another is achieved. The apparatus 528 can be assembled with bundles of the inserts 502, which are enclosed in sealed and pressurized vessels 530. The vessels 530 include the multiple inserts 502 as well as multiple turbulators 526. Fluid enters the void 510 via inlets 532 and exits via outlets 534. The combination of series and parallel connections of the grey water and cold water inlets and outlets of the fluid circuits provides improved heat exchange performance in a variety of circuit combinations and connections.

Built-in options may be included within any of the heat exchange apparatuses described herein in order to increase overall system performance and durability. These options include thin wall elements; laminar flow disruptor elements; check valve systems; one or more external level indicators; anti scaling capabilities such as, for example, mechanical devices and passage configurations to reduce scaling, anti-scaling coatings, vibration, chemical, and electrical means; anti corrosion means such as, for example, electrical, chemical, anodic, cathodic, and coatings; and water hammer protection such as, for example, shock absorbers, flexible or relatively soft and elastic cold water circuit components. Additional features may include use of an insulating shell on the systems and subsystems. System leaks and malfunctions can be detected in a variety of ways using, for example, relative flow measurement and/or pressure transducers and gauges located at strategic points in the heat exchange apparatus. Extrudable capillary fin geometry, as well as flow disruptors and other structural elements can be made of glass or Pyrex. The heat exchangers may be self draining in both horizontal and vertical positions. Individual heat exchanger modules or cylinders or heat exchanger bundles can be positioned at the top or at the bottom of larger vessels, such as with the vessels 530 described above, depending on heat exchange requirements in a given application. If electric power is required for monitoring or control equipment, power sources such as batteries, thermoelectric, or micro-turbines can be advantageously used in combination or alone.

Referring to FIGS. 21A, 21B, 21C and 22A, an alternative design of a heat exchange apparatus is shown generally at 600. The apparatus 600 can be used in shower applications and can advantageously be packaged into an enclosure of modest dimensions, and easily inserted as a component of existing or new plumbing systems, with or without a check valve (not shown). The apparatus 600 comprises a tray 602, a grey water area cover 604 and a channel member 606. Two end plates 608 each include a grey water opening 610 are located at the ends of the channel member 606. The channel member 606 includes an angled entry portion 612 and an angled exit portion 614. The angled portions 612 and 614 are angled inwardly away from the end plates 608. Cold water is communicated into and out of the apparatus via cold water connectors 616 and flows along a cold water passageway 618. As it is generally the case with the other Heat Exchanger embodiments described above, grey water area cover 604 may optionally include internal auger guiderails (not shown) to allow the passage of a plumber's drain observation and cleaning tools inserted into either of the two grey water openings 610, without interfering with the flow of grey water along the channel member 606. The tray 602 includes cavities 620 and entry and exit manifolds 622. Cold water turbulators (not shown) may be located in the cavities 620 and inside the cold water passageways 618 between the cold water entry and exit manifolds 622. The tray 602 and the cover 604 may be combined into a single piece if desired. The turbulators increase the thermal performance of the system by creating turbulent flow within the cold water passageways 618. As best illustrated in FIG. 21C, when viewed in cross section, the channel member 606 comprises a heat exchange wall 624 of minimal thickness. The heat exchange wall 624 defines a plurality of troughs 626, along which the grey water travels, and a corresponding plurality of square topped peaks 628. Located adjacent the heat exchange wall 624 is the cold water passageway 618. The heat exchange wall 624 corresponds to the distance traveled by the heat from each of the troughs 626 to each of the cold water passageways 618. This capillary configuration provides exceptional heat exchange performance between the troughs 626 and the cold water passageway 618. The very small thickness of the capillary heat exchange wall 624, combined with very large heat exchange surfaces can be achieved using specific geometries and high strength materials such as, for example, stainless steel, copper, gold, and the like, to form hollow fin members, leading to higher thermal performance than those obtained when solid material are used. It is well known in the art that thermal performance in relatively low temperature cases, such as with the heat exchange apparatuses described herein, thermal energy transfer performance depends on the following factors: heat exchange area, physical material properties (heat transfer rate), material thickness, flow turbulence (convection) in each fluid, and thermal gradient present between the two fluids. The heat exchange apparatus 600 advantageously uses a corrugated foil to form the thin heat exchange wall surface 624 with a large surface area. A stiffening surface 630 is attached to the lower end of the troughs 626 at fastening locations 632 using fastening means such as, for example, brazing, seam welding or spot welding. This allows the location of the channel member 606 into a vessel that can be pressurized at will, while maximizing heat exchange surfaces of the fin members.

Referring now to FIG. 22B, the grey water passageway can enter the heat exchange apparatus at two distinct levels, as indicated by arrows 1 and 2 with respect to grey water channel planes 627, 629. Arrow 2 above the higher plane 629 advantageously promotes debris passage in the grey water channel, albeit at the expense of drainage system slope disruption when installed in existing drainage systems such as during renovations. Also, the exit of the apparatus can be done in two different configurations with respect to the plane 627, the exit being either coplanar with the grey water channel or below, as illustrated by arrows 3 and 4.

Blade-Type Heat Exchange Apparatus

It is to be noted that in the heat exchange apparatuses 10, 76, 100, 200, 300, 500, and 600 described above, the grey water was described as the “first fluid” and the cold water was described as the “second fluid”. In the following embodiments, for ease of description of the heat exchangers, the cold water is now referred to as the “first fluid” and the grey water is now referred to as the “second fluid”

As best illustrated in FIG. 23, we have now designed a so-called blade-type heat exchange apparatus, which comprises one or more hollow blade members 638, each blade member having a first fluid (cold water) inlet 639 and a first fluid outlet 641 and a first fluid passageway 643 for a first fluid extending therebetween. The hollow blade members 638 are sized and shaped to be located in a second fluid passageway 645 for a second fluid (grey water). The blade members 638 are configured to enhance thermal energy transfer between the fluids as they flow along their respective passageways. The blade members 638 can be each manufactured from suitably formed thin sheet material, and spot or seam welded, or brazed and individually assembled. A plurality of hollow blade members 638 can be arranged substantially parallel to each other and assembled as a heat exchange apparatus in which the blade members 638 are connected together using fasteners 640. Each blade member 638 can be removed, tested for quality and re-assembled in the heat exchange apparatus. Also included is a cold water manifold 622 having a plurality of slots 623. The blade members 638 can also be assembled using mechanical components such as O-rings and gaskets, or they can be fastened by more permanent means, such as welding or brazing. In the latter case, the heat exchange apparatus can be made exclusively from welded or brazed thin sheet material, using well known high volume manufacturing techniques and quality control procedures in order to provide a high quality heat transfer and a durable system. Vents to the atmosphere may also be included in the assembly such as via an opening (not shown) adjacent to the manifolds 622.

Referring now to FIGS. 24A and 24B, the hollow blade member 638 includes a plurality of projections 649 located either on an inner wall surface 641 a or on an outer wall surface 645 or on both surfaces of the blade member 638. The projections 649 can be located on a portion of the aforesaid surfaces or, as illustrated, can be located along the entire length of the outer surface 645 of the blade member 638. The projections 649 can be any shape such as ridges, chevrons, pads, discrete nubbins and the like. Furthermore, the projections 649 may themselves comprise well defined surface roughness and additionally include microscopic projections extending therefrom. The projections 649 can be embossed on the surfaces 641 a or 645, or they may be added to a smooth surface of the blade member. Surface texture (roughness) increases the frictional forces acting between the fluid and the surface leading to higher turbulence. For household and industrial applications, the cold water passageway 643 of each blade member 638 typically operates under pressures of approximately 500-100 psi for a duration of about thirty years, therefore it is desirable to reinforce the blade members 638 to increase their lifespan. The projections 649 provide increased burst resistance to the passageways 643 by reinforcing and stiffening the blade members 638. Furthermore, the reinforcement that the projections 649 provide allows the use of very thin walls, hence providing improved thermal exchange performance. Moreover, the projections 649 can be used to align the cold water passageways among themselves within the assembly, and with an outer shell 647. Advantageously, the projections 649 control the fluid flow and enhance the thermal energy transfer between the grey water and the cold water by promoting and sustaining turbulent flow in the grey water or the cold water, or both, as they travel along their respective passageways. Additionally, the projections 649 enhance the thermal energy transfer between the grey water and the cold water by disrupting laminar flow and causing shear in the grey water, the cold water or both. The projections 649 can be incorporated to increase thermal performance, by modifying and controlling the flow of either or both fluids by a suitable configuration, while determining, aligning, and maintaining the geometry of the individual heat exchange blade members as well as the geometry of their assembly. Additionally, the projections 649 may be extended from the blades 638 into the top of the grey water passageway (not shown) to help guide the passage of plumbing tools traversing the heat exchanger during maintenance, repair, or inspection activity. Also, alignment and sealing mechanisms and devices either directly or indirectly involved with the thermal energy exchange of the heat exchange apparatus, may be used and are constructed of metallic or non-metallic materials. Various fastening systems such as welding, brazing, adhesion, cohesion, mechanical fasteners and seals and the like can be used to position, assemble and attach turbulator sub-system components into the heat exchange apparatus. An additional advantage of the projections 649 is that they provide cold water anti scaling action and grey water anti clogging action created through suitable cold water and grey water water speed and water direction management geometries, which in turn increases the useful life of the blade members and decrease maintenance needs.

As best illustrated in FIGS. 25A and 25B, the location of the projections 649 along the surfaces of the blade members 638 causes induction of flow patterns as shown by arrows 642. The projections 649, in this case, ridges, are orientated in such as manner that when cold water passes through the blade member 638 it is de-laminated as well as rotated as shown by the arrows 642 so as to generally induce shear and turbulent flow in the cold water passageway 643. Similarly, in a contraflow configuration, rotation is also induced in the grey water channel by the same shaped projections 649, as illustrated by arrows 644, which enhances turbulent flow in the grey water. The ridges 649 can be stamped into or out of the flat surface of the blade 638 or they can be added as sub-systems as described above.

Referring now to FIG. 26, an embodiment of a high pressure blade type heat exchange apparatus 800 is shown which comprises a bundle 801 of hollow blade members 802 formed and stamped from stainless steel sheet and welded and connected through a manifold to form the apparatus, which is then assembled inside a low pressure, atmospheric drain system envelope 803 through which grey water 804 flows by gravity. Each blade member 802 is made from a stainless steel sheet that is formed to obtain a hollow “flat” tubular shaped passageway where the general shape is other than cylindrical. Each blade member 802 includes a plurality of angled ridges 805 or other tubulators located on at least a portion of a blade surface, and/or as an alternative turbulators may be inserted inside the blade or positioned outside the blade as a discrete mechanical component.

Referring now to FIGS. 27, 28A and 28B, it is possible to increase the performance of the blade type heat exchange apparatus described herein by using blade members, which are based on cylindrical, corrugated heat exchanger piping (also known as “club grips”). As illustrated, a number of designs of “club grips” are known in the art and have wall exchanger surface dimensions that are maximized by the surface patterns. The patterns provide internal and external helical or “threaded screw motion” of the fluids resulting in fluid rotation. However, club grips lack the ability to maximize fluid shear and fluid turbulence. As best illustrated in FIGS. 28A and 28B, our blade design is based on a flattened club grip and provides inwardly disposed projections 810, which project into the cold water passageway 806, and outwardly disposed projections 812, which project outward, typically by stamping during the manufacturing process, from flat walls 814, and which provides unexpectedly high chaotic blade passageway geometry, leading to high levels of shear and turbulence generated in the displaced fluids. Seam welds 816 are located along the length of the blade member 802. Additional indentation shapes such as sharp bends and corrugations are also permissible, as are additional components (not shown) that can be welded onto either one or both sides of the originally flat and smooth heat exchanger walls (or by a combination of both) in order to delaminate and agitate the flow (i.e. induce shear and turbulence) of cold water flowing in the cold water passageway 806, as well as grey water flowing outside the blade member 802 and in contact with the outer surface of the blade member 802. It is to be noted that the chaotic helical cross flow motion of fluids is obtained in the pressurized fluid, such as the cold water flowing in the cold water passageway and also in the atmospheric fluid, such as the grey water flowing externally of the blade member 802. It is to be noted that the helical “club grips”, typically made from copper tubing, and other similar style “round” tubing may also be employed in the high pressure apparatus 800, whether straight or with 90 degrees bent ends, in place of the “corrugated flat wall” stainless steel hollow blade members. Additionally, turbulators can be inserted into the blade members 802.

It is known that greater thermal transfer performance and ease of manufacturing are obtained by using a thin formed sheet material in the manufacturing process of the heat exchanger components. Using thin wall stainless steel composite sheets of approximately 0.015″ to 0.035″ thicknesses in heat exchanger apparatuses provides low resistance to burst due to possible excessive high internal cold water pressure, such as those commonly used in household or industrial plumbing systems.

Referring now to FIGS. 28B and 29, an example of a stiffened geometrical heat exchange blade member, which includes fasteners 820 to maintain the structural integrity of the blade member. It is therefore useful to use geometries of wall stiffening corrugation as well as fasteners 820 where they can self reinforce the structure of the pressurized cold water passageway. The fasteners 820 may be rivets, adhesives, or seam welds 816, as described above, as well as spot welds. In order to maximize thermal energy transfer as well as structural parameters, the internal projections 810 and the external projections 812 with respect to the originally flat blade surfaces 814 and multiple blades located together may intimately contact each other for added in a fastened confirmation structural stability. The blade members 802 can be manufactured by stamping, bending and crimping an originally flat metal sheet. This can be advantageous when compared to using relatively slow linear welding to produce the seam weld 816. It is possible to use a combination of high speed edge crimping methods and tools to produce crimped areas 824 in the sheet 814. Methods and tools, such as those used to produce canned goods in the food industry can be used, with the use of optional adhesives or sealants to ensure seal intergrity where required. One such particularly useful technique, when long and straight seams are fabricated, is named “Swage Roll”, in which the assembly of two sheets of metal is done by using compression wheels that shape and form a sealed seam between the two sheet metal surfaces. Progressive dies are also used for even faster forming and sealing assembly of such parts.

Double Wall Construction

Cross-connection of plumbing devices is ruled by strict, but variable, local regulations, where grey water and fresh cold water are present within the same heat exchanger apparatus. Universally, a double wall design is preferred over any other protection means to prevent fresh water contamination by grey water in the event of system failure, such as if the heat exchanger wall is ruptured or pierced.

Referring now to FIGS. 30A and 30B, for single walled construction of a hollow blade member, that is, one without a lining such as a bladder, the external wall surfaces 840 and the internal wall surfaces 842 are the thermal transfer surfaces of the blade member and provide two work surfaces. For the double wall blade construction, four heat exchange “work” surfaces are available. In the double wall construction, as illustrated, the internal wall (bladder) 850 includes an inner thermal transfer surface 852 and an outer thermal transfer surface 854, and the outer wall includes the internal wall surface 842 and the external wall surface 840. An inter-surface space 856 is a void located between surfaces 842 and 854. The space 856 creates the separation between the blade surfaces in the double wall configuration, and allows atmospheric venting via a vent 860. The bladder 850 optionally includes a sealed wall overlap portion 862 located adjacent the vent 860. The overlap portion 862 is sealed using a weld or adhesive. The bladder 850 further includes a cold water inlet 864 and a warmed water outlet 866. The bladder 850 is constructed of a relatively flexible, possibly pre-crushed and later pressure expanded, micro-corrugated, folded, ribbed or patterned material, with a typical wall thickness of between 0.001 inch to 0.015 inch. A metallic material is preferred, but other wall compositions are contemplated. As best illustrated in FIG. 30B, the double wall configuration includes macroscopic peaks (or ridges) 812 and a macroscopic recesses 810. Microscopic textures 844 a and 844 b are located on respectively the external and internal surfaces 840 and 842, and microscopic textures 845 a and 845 b are located respectively on the external and internal surfaces 854 and 852. The microscopic textures provide additional surface turbulence to the fluids in motion.

The shell 802 of the blade assembly is essentially the same as in the single wall construction described above except for the fact that a plurality of atmospheric venting ports 860 are present in order to immediately evacuate any fluid penetrating into the defined inter-surface zone space 856. Leaking fluid immediately evacuates to the atmosphere either by gravity or by water pressure, whichever is greater, and depending on the origin of the leak. Leaking fluid evacuation is, however, increased by the textures described above. The inner pressure of the cold water compresses the bladder 850 with great force against the pressure bearing surface of the external shell 802 to provide acceptable heat transfer rates between the grey water and cold water. A suitable thermal paste or porous filler material may be optionally used to fill the inter-surface zone space 856 to further enhance the thermal transfer rate.

Blade surface dimensions and shapes, areas and thicknesses, wall and surface compositions and the nature of the material used to construct the blades, as well as surface treatment, macroscopic and microscopic surface shape and texture, all determine the blade's ability to transfer heat and become non-adhesive, or self-cleaning. Additionally, non adhesion of dirt, soap, scum, hair and debris to all heat exchanger walls and surface features, can be controlled by fluid flow management by fluid velocity and surface turbulence control, as well as chemical anti-fouling and surfaces geometrical self-cleaning properties.

Referring again to FIGS. 25A, 25B, 30A, 30B and 31A, blade wall surface geometry controls and generates both deep (macroscopic) and surface (microscopic) directional turbulence mechanisms in given fluid dynamic conditions, resulting in combined and mutually reinforced convection patterns 642, 644, and 858, which enhance fluid-to-fluid heat transfer rate and performance. The increased heat transfer rate is obtained by the sum of a surface (or microscopic) fluid velocity caused by microscopic fluid surface textures 844 a, 844 b, 845 a and 845 b, which act as turbulators, on the heat exchanger walls as well as those turbulences created macroscopically as shown by the convention patterns 642, 644. The microscopic textures 844 a, 844 b, 845 a and 845 b are used to further delaminate the fluids circulating within the larger internal and external projections (ribs or ridges) 810, 812. A variety of microscopic and macroscopic shapes and textures are contemplated and may be combined to achieve maximum turbulence. Within the space 856, the textures 844 a, 844 b, 845 a and 845 b are used to increase atmospheric venting efficiency, by providing an easier path to eventual leaks to the atmospheric vents 860.

Referring again to FIG. 30B, 31A and now FIGS. 32A and 32B, different patterns and strategies can be used or combined on different sections of the blades as well as individual fins, as described above, to maximize heat transfer rates for the whole blade assembly. In one example, a “golf ball icosahedron” surface pattern 832 in a specific location, such as on the nose of the external surface 840 of the blade, can be used to greatly reduce the accumulation of material, such as hair, at this particularly critical location.

Blade Member Design Variations

It should be noted that the wall materials, shapes, thicknesses, widths and heights, surface textures and cross sections of the blade members and of their inner components do not need to be symmetrical, fixed or constant in any manner with respect to given geometrical axes of the assembly. For example, it is possible to use a blade with a large “front-end” and a slimmer “tail-end”, in order to precisely control heat transfer surface dimensions and corresponding heat transfer rates between two fluids in cross-flow configurations. Variations where the effective cross section and the height and width of a blade or inter-blade spacing varies according to a mathematical function along the length of the blade or blade bundle assemblies are also contemplated to further enhance performance.

One of the advantages of the blade assembly is that whole assembly or even an individual blade can be removed for cleaning, inspection and maintenance and replaced if necessary. Moreover, the grey water can flow unfiltered along its passageway. Specialized cleaning tools such as wire brushes or enzyme or bacteria based solutions, as well as chemical cleaners, or combinations thereof can be periodically applied via the floor drain of the shower in order to dissolve any dirt accumulated over time on the heat exchanger grey water walls within the drainage system in order to maintain optimal said grey water flow characteristics and thermal transfer rates of the system, without affecting the environment or the drainage components in any significant matter. A strainer located at the grey water floor drain will also advantageously reduce debris entering the drain.

Referring now to FIGS. 33, 34, and 35, a plurality of blade members 802 are illustrated for use in a blade-type heat exchanger 868. The blade members 802 are located in a housing 870 in which a lower portion 874 of the housing 870 is optionally open to allow atmospheric venting in double wall configurations. The of the manifolds 622 are located substantially lower than the lower plane 627 of the grey water passageway and are also optionally open to allow atmospheric venting. The blade members 802 are located substantially parallel to each other with gaps 876 between each blade 802 which define a grey water passageway 847. In the embodiment shown, each blade member 802 has first and second walls 853 and 855, each with an inner thermal transfer surface 849 and an outer thermal transfer surface 851. Each wall 853, 855 includes a plurality of ridges and recesses 844, 845 located thereon. As illustrated, the ridges and recesses 844, 845 are disposed diagonally relative to a longitudinal axis 878 of the blade member 802 in one direction along the first wall 853 and disposed in opposite directions along the second wall 855 relative to the first wall. This arrangement of ridges and recessed defines a “criss-cross” pattern, when viewed from the side in which a central cross area 857 is a location where opposing ridge of opposing inner thermal transfer surfaces make contact. Although not illustrated, it is to be understood that similar ridges and recesses may also be located in the grey water passageway. This alternating pattern of ridges and recesses induces high levels of shear within the fluids leading to rapidly developing turbulent flow conditions in both the cold water and the grey water by causing cross flow near or at the central cross area 857, and on the planes located in the centre of the fluid passageways.

When the ridges and recesses 844, 845 are disposed diagonally, the relative “criss cross” configuration of the ridges on the walls of the blade members causes high levels of fluid shear, turbulence and cross flow within both the grey water and the cold water. However, it is to be understood that the ridges and recesses may be orientated at any angle relative to the longitudinal axis of the blade member, and may also interdigitate, or contact with each other at the central cross area, or they may be spaced apart from each other. In the example shown, the manifolds 622 for receiving the cold water are disposed generally orthogonal to the longitudinal axis 878 of the blade members and downwardly away from the longitudinal axis, as best shown in FIG. 33. In this example, the housing 870 together with the plurality of blade members 802 can be located in a tray 879 through which the grey water is flowing or the blade members 802 can be manufactured as a unitary body with the tray located near the lower portion of the blade members 802. The grey water passageway 847 dimensions will depend largely on the nature of the debris that is expected to be found in the grey water as it flows along the passageway 847 as well as on the fluid characteristics, such as volume, velocity and viscosity, expected in normal operating conditions also in order to optimize heat exchanger performance. A screen (not shown) can be used over the entrance to the grey water passageway 847 to prevent debris from entering the grey water passageway 847. The screen can be located before the P-trap in a household shower/bath system. Moreover, the shape and location of each blade member 802 can be changed to allow passage of a variety of debris types and fluid hydrodynamic characteristics. Thus, the grey water flowing along its passageway 847 contacts the outer thermal surfaces of the plurality of blade members 802 such that turbulence is induced in the grey water, while simultaneously, turbulent cold water moving along the cold water passageway contacts the inner thermal surface thereby allowing for efficient thermal energy transfer across the walls of the blade members 802.

Ridges can be evenly spaced and shaped (depth and 3D forms) or follow a pattern defined mathematically along the blade walls, to increase blade surfaces and generate turbulent flow for various grey water and cold water flow conditions, thereby maximizing heat transfer. Fluid shear inducing ridges may be located at the bottom of the grey water passageway 847. Additionally, scale-type/shaped ridges can be used to create turbulent flow at the bottom of the grey water passageway 847, with a reduced risk for clogging. The same scales structure may be useful for location on the periphery of vertical heat exchange embodiment, as described below.

In the example illustrated in FIG. 36, a bottom tray 880 is designed to receive a plurality of the blade members 802 in a pre-defined grey water passageway 881. In the example illustrated, the manifolds 622 are disposed upwardly away from the longitudinal axis 878 of the blade members 802. This design aids the location of the blade members 802 into the tray 880. This design is particularly well suited large laundry facilities such as those used in hospitals where a large of volume grey water is generated and flows in open channels when discarded at high temperatures. The heat exchangers of this design can be easily retrofitted into the existing plumbing and easily maintained and cleaned by lifting the blade member assemblies from the grey water passageway.

As best illustrated in FIGS. 373 to 40, the scale of the design may be increased substantially to include a plurality of blade members 882 of larger dimensions, namely in increased height dimensions leading to a further theoretical increase in convective heat transfer performance. A housing 884 is designed to accommodate the larger blade members 882 and includes inlet and outlet grey water pipes 885, 886 and inlet and outlet cold water pipes 888, 890. The housing 884 includes a removable upper portion 892, which allows for easy access to the blade members 882. Referring now to FIG. 39, the larger dimension blade member 882 include a plurality of ridges and recesses 894, which cover substantially the entire surface areas of each inner and outer sidewall of each blade member. For ease of illustration, only one outer sidewall is shown in FIG. 46. As above, the criss-cross pattern of ridges (ribs) causes shear and turbulence in the flow of both the grey water and the cold water traveling along the internal and external portions of the blade. The pattern of ridges may include other previously mentioned shapes and may comprise combinations of them. The orientation of the grey water flow may be orthogonal to the flow if the cold water as is illustrated by the location of the grey water inlet and outlet pipes 885, 886 in FIG. 40. Additionally, a plurality of spot weld points 896 and/or seam welds 898 are located to fasten and seal each sidewall of the blade members together. If a double wall design is used, the welds can pass through the opening in the bladder, which is sealed around the punctured holes to maintain integrity of the double wall. Additional features of the larger blades 882 include a plurality of flow management disrupters 899 located along the edges of the blades 882.

In the previously described examples of the blade-like heat exchange apparatus, the manifolds are disposed downwardly away from the longitudinal axis 878 of the blades to facilitate maintenance. This design is for use in household shower arrangements in which water typically drains at 10 litres/hour. For commercial applications, however, the manifolds may be disposed upwardly away from the longitudinal axis 878 of the blades. In larger applications, the larger blades are rigidified by welds and can also provide a double wall arrangement. The bladder is punctured and sealed around each structural weld. Moreover, if required, a section of the blade can be enlarged by adding additional sections of blade thereto. The additional blade sections can be embossed with flow disrupters. Alternatively, one can use a turbulator insert to induce flow turbulence inside the blades.

Referring now to FIGS. 41, 42, 43, 44A and 44B, another example of a heat exchange apparatus is shown generally at 900 and is particularly useful, but not limited to applications when used in a vertical orientation, that is, the apparatus is disposed generally orthogonal to the ground. In this design, a housing 902 is generally tube-like and includes a central grey water conduit 904, around which is disposed a cold water passageway 906 having an inlet 908 and an outlet 910. The cold water passageway 906 includes a double “slinky” turbulator 912 which is modeled on the wire “slinky” children's toy, which efficiently generates shear forces within the fluid when the slinkies are arranged in a clockwise and counter clockwise configuration producing a criss cross pattern such as the one illustrated. Also, slinkies are highly flexible and will allow the heat exchange apparatus to be used in locations that require bending of the grey water and cold water passageways. One wire of the slinky 914 is coiled around the grey water passageway in clockwise orientation and the other wire 916 of the slinky is coiled in a counter clockwise orientation relative to the longitudinal axis of the grey water conduit 904. As in a hollow blade 802, 638 or 882 the “double helical” criss cross arrangement of the two slinky wires creates a turbulator and promotes high turbulence in the cold water flowing downwardly or upwardly such that the cold water is constantly sheared all within a single cavity located around the grey water passageway, such as that described for within the blade member 802. Additionally, where each of the slinky wires 914, 916 crosses each other, a cross area 911 is formed which is similar to the central cross area 857 described above for the ridges 844. Cold water when following the path defined by the slinky wire 914 travels in one direction, and simultaneously when follows the path defined by the slinky wire 916 travels in an orthogonal direction, very high shear and turbulence is induced within the cold water passageway 906. Since this highly turbulated cold water is trapped in the cavity between the housing 902 and the grey water conduit 904, highly efficient heat exchange occurs between the optionally smooth thermal transfer surfaces of the conduit 904. Again, the shearing effects is similar to the one that is caused by the criss cross surfaces of the design as described above. This heat exchange design advantageously allows the design of compact and pressure self supporting heat exchange apparatuses, which can be used either with the single wall configuration as described or with a bladder to provide the double wall capability. For increased heat exchange performance, a turbulator 108 can be located inside the grey water passageway 904.

Referring now to FIGS. 45A to 45C, a mesh type turbulator 918 is shown in the heat exchanger. The mesh type turbulator 918 includes a plurality of criss crosses 911, which are defined by a first plurality of clockwise helically orientated wires and a plurality of other helical wires disposed counterclockwise to the first plurality of wires. Although not illustrated, the mesh may also include a plurality of orthogonally orientated wires. The turbulator mesh can comprise of a variety or a combination of shear inducing short path turbulent flow inducing surfaces such as, but not limited to, perforation open cell porous medica, molded, composite, stacked, slit, interdigitated, semi-rigid and symmetrical, textured elements. As described above, turbulators may be inserted in the grey water passageway or also in the cold water passageway.

An alternative to the double helical wire criss cross turbulator is a double slinky wire criss cross turbulator which consists of an insertion of a single clockwise slinky wire into a counter-clockwise patterned corrugated tube (club grip) or even into an axial internal finned tube or any other criss cross generating wire pattern.

Compact Heat Exchangers

As best illustrated in FIGS. 46A to 46H, and 47A and B and 51, a compact heat exchange apparatus 1000 is a generally arcuate blade, where criss cross turbulator 1001 is located in a cold water passageway or could be imprinted on the surface of the blade as described above for the other embodiments. The criss cross turbulator 1001 includes a series of helically and diagonally disposed ribs 1006 and 1006.

The suitably dimensioned blade can be located inside a tubular pipe 1002 for heat exchange of calibrated or known volumes of grey water and cold water. The heat exchange apparatus 1000 can also be located externally of the tubular pipe 1002. In another example, the tubular pipe 1002 may be manufactured such that the arcuate heat exchange apparatus is integral with the pipe sidewall.

The arcuate blade heat exchanger apparatus 1000 can be used singly for applications in which a small volume of grey water is traveling along the pipe 1002 and located adjacent the area of the pipe where heat is to be exchanged. The arcuate design of the heat exchange apparatus means that multiple arcuate heat exchange apparatuses can be used to fully or partially encase the pipe 1002. Two or three or more arcuate blade heat exchange apparatuses 1000 can be used to fully encase the pipe 1002. Also, if the arcuate blades are located inside the pipe, the arcuate blades are typically constructed from metal with the turbulators 1001 located on one or both sides of the blade. If located outside the pipe, the blade is manufactured with metal on one side and the turbulators 1001 on one or both sides or inserted. Metal surfaces on both sides of the arcuate blade along with turbulators is a favoured construction for the blades.

Sections of the compact designs are particularly useful for drain pipe heat exchange applications where drains are installed in a position other than vertical relative to the ground, and where one side of the pipe carries the energy to be exchanged.

Although in the examples described above, hollow, planar blades and hollow arcuate blades have been described, it is to be understood that the blades can be of any three-dimensional shape, such as cylindrical, conical, triangular, disk-like, and the like. Moreover, we also contemplate that planar hollow blades having surface projections and recesses can be formed into a tube, the tube being optionally open along the longitudinal axis in order to be attached and clamped onto a central grey water drain.

Referring now to FIG. 46, a control system 700 may be used to monitor or to control the function of any of the heat exchange apparatuses described herein. This is particularly useful if the heat exchange apparatus is to be imbedded in a wall or behind an inaccessible structure. Moreover, if multiple heat exchangers are being used throughout a building, the ability to monitor the functions such as the performance or the energy transfer of the individual heat exchangers is advantageous. Thus, the system 700 may include a unidirectional or a bi-directional data transmission and communication, data acquisition function. The physiochemical properties of the fluids flowing in the heat exchangers can be monitored by the control system 700 and any changes to such can be monitored and a user alerted if any deleterious changes occur. This is particularly useful in heat exchangers that are used in the food, pharmaceutical, farming and water treatment industries. The control system 700 is constructed and programmed, and can be a wireless system, as well as conventional wire assisted system or alternatively, a combination of both and individually embedded or externally integrated to one or more heat exchanger systems. The system 700 can be manually operated, or computer controlled using telemetric applications involving well-known standard process operation parameters measurement, analysis and data acquisition at strategic locations such as, but not limited to entry and exit points. Additional parameters that can be measured and monitored include fluid viscosities, fluid temperatures, fluid pH, fluid hardness, fluid ppm data, fluid mineral and chemical content, fluid lighting and imaging, fluid chromatography, fluid collection and sampling, fluid aeration, fluid velocity and flow rate, fluid pressure, fluid turbulence, heat exchanger sub-systems and overall system integrity and malfunction detection, heat exchanger system overall performance, heat exchanger instantaneous workload as well as efficiency computations. Additionally, rather than measuring within the fluid or acting upon the fluid, measurements and monitoring can be carried out within the system and sub-system components such as the heat exchanger walls, discrete system components, nozzles, sensors, actuators, fluid passageways, interstitial wall components, additional sub-systems. Fluid physical properties can be monitored, data acquisition can be made, and modifications to the heat exchange system operation can also be made. Such modifications include, but are not limited to, activation of sensors and actuators, as well as passive component temperatures, vacuum levels, pressure levels, vibration, moisture as well as other process related operating parameters related to the integrity and the performance of the heat exchanger system and other sub-systems. Manually operated, or computer controlled process control applications can include the operation and actuation of valves and sensors in order to modify working parameters of the heat exchanger system as well as actively or passively modifying the fluid physical properties. Also, the system 700 can maintain or optimize the operation of individual or remotely located heat exchange apparatuses in a larger heat exchange circuit by varying the individual workload or maintenance requirements over time, or by modifying the fluids for a subsequent process in terms of physical or chemical property requirement.

In addition to monitoring the heat exchange apparatuses, it is possible to use the system 700 to monitor and compute tariffs and fees based on heat exchanger workload and efficiency or other measurable physical workloads performed by the systems over time. Energy savings provided by the heat exchanger and peripheral systems can be evaluated, charged and billed to the user.

OTHER EMBODIMENTS

From the foregoing description, it will be apparent to one of ordinary skill in the art that variations and modifications may be made to the invention described herein to adapt it to various usages and conditions. Such embodiments are also within the scope of the present invention. 

1. A heat exchange apparatus, the apparatus comprising: a hollow blade member having a first fluid inlet and a first fluid outlet and a first fluid passageway for a first fluid extending therebetween, the blade member being sized and shaped for location in a second fluid passageway for a second fluid, the blade member being configured to enhance thermal energy transfer between the fluids as they flow along their respective passageways.
 2. The apparatus, according to claim 1, in which the enhancement of thermal energy transfer is caused by turbulent flow.
 3. The apparatus, according to claim 1, in which the enhancement of thermal transfer is caused by reduction of laminar flow.
 4. The apparatus, according to claim 1, in which the enhancement of thermal transfer is caused by shear within the first and second fluids.
 5. The apparatus, according to claim 1, in which the blade member has an inner and an outer thermal transfer surface, the inner thermal transfer surface having a plurality of spaced apart inner surface projections to induce thermal energy transfer in the first fluid, the outer thermal transfer surface being located to contact the second fluid flowing along the second fluid passageway.
 6. The apparatus, according to claim 5, in which the inner thermal transfer surface further includes a plurality of spaced apart inner surface recesses.
 7. The apparatus, according to claim 5, in which the outer thermal surface has a plurality of spaced apart outer surface projections located to induce thermal energy transfer in the second fluid as it flows along the second fluid passageway in contact with the outer thermal transfer surface.
 8. The apparatus, according to claim 5, in which the outer thermal transfer surface further includes a plurality of spaced apart outer surface recesses.
 9. The apparatus, according to claim 5, in which the inner and outer thermal transfer surfaces each have a plurality of spaced apart projections and recesses, the projections and recesses being disposed substantially parallel to each other.
 10. The apparatus, according to claim 1, in which the blade member has a longitudinal blade axis and two blade walls, each blade wall having an inner and an outer thermal transfer surface, each thermal transfer surface having a plurality of ridges and recesses disposed substantially parallel to each other.
 11. The apparatus, according to claim 10, in which the outer thermal transfer surfaces are located to contact the second fluid flowing along the second fluid passageway.
 12. The apparatus, according to claim 10, in which the ridges and recesses of the first blade wall being angled in a first direction relative to the longitudinal axis, the ridges and recesses of the second blade wall being angled in a second direction relative to the longitudinal axis, the second direction being different from the first direction so as to induce cross flow in the first and second fluids as they travel along their respective passageways.
 13. The apparatus, according to claim 10, in which the ridges located on opposing inner thermal transfer surfaces contact each other to induce cross flow in the first fluid as it travels along the first fluid passageway.
 14. The apparatus, according to claim 10, in which the ridges located on opposing inner thermal transfer surfaces are spaced apart from each other to induce cross flow in the first fluid as it travels along the first fluid passageway.
 15. The apparatus, according to claim 10, in which the ridges located on opposing inner thermal transfer surfaces are interdigitated to induce cross flow in the first fluid as it travels along the first fluid passageway.
 16. The apparatus, according to claim 10, in which the ridges located on opposing inner thermal transfer surfaces contact each other to induce turbulence in the first fluid as it travels along the first fluid passageway.
 17. The apparatus, according to claim 10, in which the ridges located on opposing inner thermal transfer surfaces are spaced apart from each other to induce turbulence in the first fluid as it travels along the first fluid passageway.
 18. The apparatus, according to claim 10, in which the ridges located on opposing inner thermal transfer surfaces are interdigitated to induce turbulence in the first fluid as it travels along the first fluid passageway.
 19. The apparatus, according to claim 1, in which the second fluid passageway is configured to induce thermal energy-transfer between the fluids.
 20. The apparatus, according to claim 1, in which the first and second fluids flow in a contraflow direction.
 21. The apparatus, according to claim 1, in which the first and second fluids flow in a parallel flow configuration.
 22. The apparatus, according to claim 1, in which the first and second fluids flow in a cross flow configuration.
 23. The apparatus, according to claim 1, in which each blade wall has a sealable blade edge to allow the blade member to be pressurized.
 24. The apparatus, according to claim 23, in which the blade member is pressurized to above atmospheric pressure or to below atmospheric pressure.
 25. The apparatus, according to claim 1, in which the blade member has a longitudinal blade axis, the first fluid inlet and the first fluid outlet being disposed orthogonal relative to the longitudinal blade axis.
 26. The apparatus, according to claim 1, in which the blade member has a longitudinal axis, the second fluid passageway has a second fluid inlet and a second fluid outlet, the second fluid inlet and the second fluid outlet being disposed coaxial to the longitudinal axis.
 27. The apparatus, according to claim 26, in which the second fluid inlet and the second fluid outlet are disposed orthogonal to the longitudinal axis of the blade member.
 28. The apparatus, according to claim 1, in which the blade member is double-walled.
 29. The apparatus, according to claim 28, in which the double wall is a lining located in intimate contact with an inner thermal transfer surface of the blade member.
 30. The apparatus, according to claim 29, in which the lining is spaced apart from the inner thermal transfer surface, a thermal transfer filler being located between the lining and the inner thermal transfer surface.
 31. The apparatus, according to claim 29, in which the lining is a bladder.
 32. The apparatus, according to claim 31, in which the bladder is made from a membraneous heat conductive material.
 33. The apparatus, according to claim 1, in which the blade member is ventable to the atmosphere.
 34. The apparatus, according to claim 1, in which the blade member further comprises a lining located in intimate contact with an inner thermal transfer surface of the blade member, the lining defining a double wall, the blade member being configured to allow the first fluid to drain away from the first passageway or the second fluid from the second fluid passageway, if either of the passageways breaks.
 35. The apparatus, according to claim 1, in which the first or second fluids flow by gravity.
 36. The apparatus, according to claim 1, in which a turbulator is located in the first fluid passageway.
 37. The apparatus, according to claim 1, in which a turbulator is located in the second fluid passageway.
 38. The apparatus, according to claim 1, in which the second fluid passageway is pressurized to above atmospheric pressure or below atmospheric pressure.
 39. The apparatus, according to claim 1, in which the first fluid is cold water and the second fluid is grey water.
 40. A blade heat exchange apparatus, the apparatus comprising: at least one blade member having a first fluid inlet and a first fluid outlet, and a first fluid passageway for a first fluid extending therebetween, the blade member having a longitudinal blade axis; a second fluid passageway for a second fluid, the second fluid passageway being sized and shaped to receive therein the blade member; the blade member has two blade walls, each blade wall having an inner and outer thermal transfer surface, the thermal transfer surfaces each having a plurality of spaced apart ridges and recesses, the ridges and recesses being substantially parallel to each other, the ridges and recesses of the first blade wall being angled in a first direction relative to the longitudinal axis, the ridges and recesses of the second blade wall being angled in a second direction relative to the longitudinal axis, the second direction being different from the first direction so as to induce cross flow in the first and second fluids as they travel along their respective passageways.
 41. The heat exchange apparatus, according to claim 40, the ridges located on the inner thermal transfer surfaces of the blade walls contact each other, are spaced apart from each other, or are interdigitated.
 42. The heat exchange apparatus, according to claim 40, in which the second fluid passageway is a channel located in a tray.
 43. The heat exchange apparatus, according to claim 40, in which a plurality of blade members are mounted substantially parallel to each other.
 44. The heat exchange apparatus, according to claim 40, in which a plurality of the blade members are stacked on top of each other and define a plate.
 45. The heat exchange apparatus, according to claim 40, in which a plurality of the plates are mounted in a housing, the housing having a first fluid inlet and a first fluid outlet.
 46. The heat exchange apparatus, according to claim 40, in which the blade member is double walled.
 47. The heat exchange apparatus, according to claim 40, in which the blade member is ventable to the atmosphere.
 48. The heat exchange apparatus, according to claim 40, is located downstream of a drain trap.
 49. The heat exchange apparatus, according to claim 40, in which the first fluid passageway includes a turbulator.
 50. The heat exchange apparatus, according to claim 40, in which the second fluid passageway includes a turbulator.
 51. A heat exchange apparatus, comprising: a central conduit having a conduit wall; an outer jacket substantially encasing the central conduit, the jacket being spaced apart from the conduit wall to define an enclosure and having a fluid inlet and a fluid outlet; a turbulator located in the enclosure, the turbulator having a first helical wire disposed in a clockwise orientation and a second helical wire disposed counterclockwise to the first helical wire so as to induce turbulent flow in a fluid as it contacts the turbulator.
 52. The heat exchange apparatus, according to claim 51, in which the first and second helical wires cross each other and induce cross flow in the fluid as it contacts the helical wires.
 53. The heat exchange apparatus, according to claim 51, in which grey water flows along the central conduit.
 54. The heat exchange apparatus, according to claim 51, in which cold water contacts the turbulator.
 55. The heat exchange apparatus, according to claim 54, in which the cold water flows by gravity.
 56. A heat exchange apparatus, the apparatus comprising: a central conduit having a conduit wall; an outer jacket substantially encasing the central conduit, the jacket being spaced apart from the conduit wall to define an enclosure and having a fluid inlet and a fluid outlet; a mesh turbulator located in the enclosure, the mesh turbulator being configured to induce turbulent flow in a fluid as it contacts the turbulator.
 57. The apparatus, according to claim 56, in which the mesh turbulator includes a first plurality of helical wires disposed in a clockwise orientation and a second plurality of helical wire disposed counterclockwise to the first plurality of helical wire.
 58. The apparatus, according to claim 56, in which the mesh turbulator includes a plurality of orthogonally disposed wires.
 59. The apparatus, according to claim 56, in which the central conduit and the enclosure further include turbulators.
 60. A heat exchange apparatus, the apparatus comprising: at least one hollow fin member having first and second thermal transfer surfaces, the first thermal transfer surface defining a first fluid passageway for a first fluid, which first fluid being flowable along the first passageway in contact with the first thermal transfer surface; and a second fluid passageway for a second fluid, the second fluid passageway being located in intimate contact with the second thermal transfer-surface, such that the first fluid when flowing along the first fluid passageway exchanges thermal energy with the second fluid flowing along the second fluid passageway.
 61. The apparatus, according to claim 60, in which the fin members are disposed substantially parallel to each other.
 62. The apparatus, according to claim 60, further including a turbulator disposed on the first thermal surface to induce turbulent flow in the first fluid
 63. The apparatus, according to claim 60, further including a turbulator disposed on the second thermal surface to induce turbulanet flow in the second fluid.
 64. The apparatus, according to claim 60, in which the fin members are configured as an H-shaped channel member having first and second end portions, the first end portion being connectable to a source of a first fluid, the first fluid entering the first end portion at a first temperature and flowable along the first thermal transfer surface, the first fluid exiting the second end portion at a second temperature and a second fluid passageway having an inlet and an outlet, the second fluid passageway being located in intimate contact with the second thermal transfer surface, the inlet being connectable to a source of a second fluid, the second fluid entering the inlet at a third temperature and flowable along the second fluid passageway, such that the first fluid when flowing along the first fluid passageway exchanges thermal energy with the second fluid flowing along the second fluid passageway, the second fluid exiting the outlet at a fourth temperature.
 65. The heat exchange apparatus, according to claim 60, in which the fin members are circumferentially disposed about a conduit.
 66. A heat exchange apparatus, the apparatus comprising: a conduit having an arcuate conduit member having first and second ends, and an arcuate heat exchanger having first and second connecting portions sealingly connectable to the respective first and second ends, the heat exchange having first and second thermal transfer surfaces, an amount of a first fluid entering the conduit at a first temperature and being in contact with the first thermal transfer surface and exiting the conduit at a second temperature; and a fluid passageway having a fluid passageway sidewall of a membraneous material, the material having at least one heat conductive surface locatable in intimate contact with the second thermal transfer surface, the fluid passageway sidewall being spreadable over an area of the second thermal transfer surface, the fluid passageway having a fluid passageway inlet and a fluid passageway outlet, a second fluid entering the fluid passageway inlet at a third temperature and exiting the fluid passageway outlet at a fourth temperature.
 67. The apparatus, according to claim 1, in which the blade member is self-supporting. 